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US4839397A - Polyurethane soft foam with sound insulating and vibration damping properties - Google Patents

Polyurethane soft foam with sound insulating and vibration damping properties Download PDF

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Publication number
US4839397A
US4839397A US07/174,692 US17469288A US4839397A US 4839397 A US4839397 A US 4839397A US 17469288 A US17469288 A US 17469288A US 4839397 A US4839397 A US 4839397A
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article
polyisocyanate
article according
adhesive
substrate
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US07/174,692
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Ernst Lohmar
Gerhard Burak
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Dr Alois Stankiewicz GmbH
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Dr Alois Stankiewicz GmbH
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B32B5/20—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material foamed in situ
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00—Polymeric products of isocyanates or isothiocyanates
    • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/08—Processes
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00—Polymeric products of isocyanates or isothiocyanates
    • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
    • C08G18/40—High-molecular-weight compounds
    • C08G18/48—Polyethers
    • C08G18/4804—Two or more polyethers of different physical or chemical nature
    • G—PHYSICS
    • G10—MUSICAL INSTRUMENTS; ACOUSTICS
    • G10K—SOUND-PRODUCING DEVICES; METHODS OR DEVICES FOR PROTECTING AGAINST, OR FOR DAMPING, NOISE OR OTHER ACOUSTIC WAVES IN GENERAL; ACOUSTICS NOT OTHERWISE PROVIDED FOR
    • G10K11/00—Methods or devices for transmitting, conducting or directing sound in general; Methods or devices for protecting against, or for damping, noise or other acoustic waves in general
    • G10K11/16—Methods or devices for protecting against, or for damping, noise or other acoustic waves in general
    • G10K11/162—Selection of materials
    • G10K11/168—Plural layers of different materials, e.g. sandwiches
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0278—Polyurethane
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/02—Cellular or porous
    • B32B2305/022—Foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/10—Fibres of continuous length
    • B32B2305/20—Fibres of continuous length in the form of a non-woven mat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B32B2307/102—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2375/00—Polyureas; Polyurethanes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/003—Interior finishings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
    • B60R13/08—Insulating elements, e.g. for sound insulation
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G2110/00—Foam properties
    • C08G2110/0008—Foam properties flexible
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G2110/00—Foam properties
    • C08G2110/0041—Foam properties having specified density
    • C08G2110/0058—≥50 and <150kg/m3
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G2110/00—Foam properties
    • C08G2110/0075—Foam properties prepared with an isocyanate index of 60 or lower
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G2120/00—Compositions for reaction injection moulding processes
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G2350/00—Acoustic or vibration damping material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/23907—Pile or nap type surface or component
    • Y10T428/23979—Particular backing structure or composition
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249981—Plural void-containing components

Definitions

  • the present invention relates to a polyurethane soft foam which is particularly suitable for sound insulation. It is characterised in that besides an air-borne sound absorption and sound insulation effect in mass-spring systems, the vibration damping effect can also be used for sound insulation, since on account of its surface properties good contact is possible with a metal sheet that is to have its vibration damping.
  • DE-PS No. 27 56 622 is concerned with manufacturing foam materials with high loss factors, the process described, namely the impregnation of open-pored polyurethane or PVC foams with viscoelastic raw materials, e.g. polyolefins or organic resins or waxes containing inorganic filling materials, is very expensive.
  • DE-PS No. 33 13 624 is also concerned with the manufacture of a polyurethane soft foan with a high loss factor.
  • the viscoelastic properties cannot be used as they are for damping vibration of sheet metal, such as e.g. bodywork floor assemblies and front walls in motor vehicles, because in order to damp vibration there has to be a coupling between the sheet whose vibration is to be damped and the viscoelastic material.
  • This is not possible in the case of the known foam materials without using supplementary means.
  • compact materials for damping vibration are today melted on to vehicle floor assemblies. This is a very expensive procedure.
  • the melting processes are generally carried out before or during painting of the bodywork, problems of paint soiling arise. Melting in separate ovens is associated with a great expenditure of energy, so that there is considerable interest in performing the vibration damping without separate melting processes.
  • the object of the invention is therefore to provide a polyurethane foam that does not have these disadvantages and, besides improving the absorption of air-borne sound and damping of air-borne sound in so-called mass-spring systems, additionally makes it possible to damp the vibration of sheet metal.
  • Polyurethane foams with this combination of properties are novel and were not known until now; they open up the broader possibilities, described in the statement of object, for new concepts for sound insulation and are thus of considerable interest.
  • the foams according to the invention are also suitable for foam backing heavy foils and carpets so that air-borne sound insulation properties can also be used besides the vibration damping effect. Owing to their low modulus of elasticity they are also suitable for use as springs in mass-spring systems.
  • the present invention therefore relates to a soft foam of polyurethane for sound insulation purposes, having an adhesive surface, which is obtained by reaction of a polyisocyanate or a polyisocyanate prepolymer with an excess of polyols or mixtures thereof employing an NCO index of ⁇ 80, more particularly ⁇ 70, and which has a density of 80 kg/m 3 -250 kg/m 3 , a modulus of elasticity of less than 300,000 N/m 2 and a loss factor of at least 0.4.
  • Suitable polyols are polyether polyols, particularly those based on ethylene oxide and/or propylene oxide.
  • foam parts preferably take place by means of the RIM (Reaction Injection Moulding) process.
  • foam parts can also be produced in a composite with other materials, such as e.g. textile inserts, fleece inserts, foam backing for heavy layers or carpets and textile materials.
  • the residence time in the mould can be limited by means of accelerators to under 3 minutes which enables an economic production of shaped parts.
  • the foam according to the invention is produced according to the state of the art rules for cold form foams (e.g. G. Woods "Flexible Polyurethane Foams", Chemistry and Technology, 1982, 206 ff).
  • FIGS. 1 and 2 show properties of the foam material obtained
  • FIGS. 3 and 4 sow in different forms, a sound insulating adhesive insulating system as a wall coating, coated on a wall part formed by a profiled metal sheet, which employs the polyurethane soft foam material according to the invention,
  • FIGS. 5 and 6 show, in different forms corresponding to FIGS. 3 and 4, a sound insulating system as a wall coating with a carpet laid over a decoupler.
  • Composition A A:
  • Composition B is a composition of Composition B:
  • the components A and the components B were then added to the mixing head of a RIM machine in the proportions given in the following table and foamed in a mounted to an open pored foam part. It was removed from the mould after 3 minutes.
  • the properties of the foam material obtained are given in the table and in FIGS. 1 and 2.
  • the weight per unit volume of the foam material was approx. 120 g/dm 3 .
  • the metal sheet forming the wall part 1 as the substrate has profiles which are followed by the wall coating, which is formed as a moulding, namely an insulation system 3 with a carpet 8 arranged over it, the same thickness of the wall coating always being maintained.
  • the wall coating is applied to the wall part adhesively without having to use glue through the adhesion at position 2 of the insulation system 3 comprising polyurethane soft foam material according to the invention.
  • the wall coating thus consists of the insulation system, 3 which in turn has as a so-called spring 4, 5, the polyurethane soft foam material and a mass 6 of filled plastics material forming a heavy layer. Local differences in the sound damping ability can be obtained by putting the springs 4, 5 on over part of the surface. If necessary uniform sound damping over the whole surface can be obtained by putting the springs 4, 5 on correspondingly over the whole surface.
  • the decoupler 7 prevents the reduction of the bending strength which can otherwise be detected when a carpet is placed on the insulating system. Moreover it is surprisingly found that not only is the acoustic effect simultaneously maintained but as a rule it is even improved. In addition such an arrangement is simple to work in the usual manner.

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  • Chemical & Material Sciences (AREA)
  • Polymers & Plastics (AREA)
  • Medicinal Chemistry (AREA)
  • Organic Chemistry (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Acoustics & Sound (AREA)
  • Multimedia (AREA)
  • Textile Engineering (AREA)
  • Polyurethanes Or Polyureas (AREA)
  • Laminated Bodies (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Vibration Prevention Devices (AREA)

Abstract

The present invention relates to polyurethane foam materials with sound insulating and vibration damping properties. They are obtainable by reacting a polyisocyanate or polyisocyanate prepolymers with an excess of polyols or a mixture thereof while maintaining an NCO index of ≦80, in particular ≦70 and as a result they have an adhesive (frictional) surface and are further characterized by a density of 80 to 250 kg/m3, a modulus of elasticity less than 300 OOO N/m2 and a loss factor of at least 0.4. The production is preferably done by adding the reaction components (polyol system on the one hand and polyisocyanate system on the other) to the mixture head of an RIM machine. The polyurethane soft foam materials with an adhesive surface according to the invention are particularly suitable for use as vibration damping sound insulation systems in automobiles.

Description

TECHNICAL FIELD OF THE INVENTION
The present invention relates to a polyurethane soft foam which is particularly suitable for sound insulation. It is characterised in that besides an air-borne sound absorption and sound insulation effect in mass-spring systems, the vibration damping effect can also be used for sound insulation, since on account of its surface properties good contact is possible with a metal sheet that is to have its vibration damping.
BACKGROUND OF THE INVENTION AND PRIOR ART
While various polyurethane soft foam materials are known for sound insulation, they are, unlike the foam according to the invention, not suitable for damping vibration. Thus DE-AS No. 19 23 161 and DE-OS No. 28 35 329 describe foam materials filled with minerals which, due to their great weight per unit volume of 0.5 to 1.25 kg/dm3, enable good sound insulation to be obtained. It is however not possible to damp the vibration of sheet metal with these materials as the loss factor of these foams is too small.
While it is true that DE-PS No. 27 56 622 is concerned with manufacturing foam materials with high loss factors, the process described, namely the impregnation of open-pored polyurethane or PVC foams with viscoelastic raw materials, e.g. polyolefins or organic resins or waxes containing inorganic filling materials, is very expensive.
DE-PS No. 33 13 624 is also concerned with the manufacture of a polyurethane soft foan with a high loss factor. However, the viscoelastic properties cannot be used as they are for damping vibration of sheet metal, such as e.g. bodywork floor assemblies and front walls in motor vehicles, because in order to damp vibration there has to be a coupling between the sheet whose vibration is to be damped and the viscoelastic material. This is not possible in the case of the known foam materials without using supplementary means. For this reason compact materials for damping vibration are today melted on to vehicle floor assemblies. This is a very expensive procedure. As the melting processes are generally carried out before or during painting of the bodywork, problems of paint soiling arise. Melting in separate ovens is associated with a great expenditure of energy, so that there is considerable interest in performing the vibration damping without separate melting processes.
An attempt has also been made (DE-OS No. 35 10 932) to use the viscoelastic properties of a foam material by applying adhesive coatings for coupling between sheet metal and foam, but the process involves additional expenditure.
OBJECT OF THE INVENTION
The object of the invention is therefore to provide a polyurethane foam that does not have these disadvantages and, besides improving the absorption of air-borne sound and damping of air-borne sound in so-called mass-spring systems, additionally makes it possible to damp the vibration of sheet metal.
SUMMARY OF THE INVENTION
This object has been achieved by the provision of a polyurethane soft foam which, owing to its composition, has an intrinsically adhesive surface and in addition a loss factor of over 0.4.
It has been discovered that the adhesive (frictional) properties which are required for the purpose of transferring damping properties, are dependant on the code number (NCO index) of a polyurethane mixture. Surprisingly, and not foreseeable by the man skilled in the art, it was discovered that optimal adhesive (frictional) properties are only attainable with code numbers between 80 and 50 (cf. FIG. 2). In addition it was also not foreseeable that just in this range of the code numbers good damping properties of the foam can also be obtained (cf. FIG. 1).
Polyurethane foams with this combination of properties are novel and were not known until now; they open up the broader possibilities, described in the statement of object, for new concepts for sound insulation and are thus of considerable interest.
The foams according to the invention are also suitable for foam backing heavy foils and carpets so that air-borne sound insulation properties can also be used besides the vibration damping effect. Owing to their low modulus of elasticity they are also suitable for use as springs in mass-spring systems.
The present invention therefore relates to a soft foam of polyurethane for sound insulation purposes, having an adhesive surface, which is obtained by reaction of a polyisocyanate or a polyisocyanate prepolymer with an excess of polyols or mixtures thereof employing an NCO index of ≦80, more particularly ≦70, and which has a density of 80 kg/m3 -250 kg/m3, a modulus of elasticity of less than 300,000 N/m2 and a loss factor of at least 0.4.
Examples of suitable polyols are polyether polyols, particularly those based on ethylene oxide and/or propylene oxide. Suitable polyisocyanates other than diphenylmethane-4.4-diisocyanate with an NCO content of 31% based on MDI, are those with different NCO contents.
The production of the foam according to the invention preferably takes place by means of the RIM (Reaction Injection Moulding) process. In this manner foam parts can also be produced in a composite with other materials, such as e.g. textile inserts, fleece inserts, foam backing for heavy layers or carpets and textile materials. The residence time in the mould can be limited by means of accelerators to under 3 minutes which enables an economic production of shaped parts.
The foam according to the invention is produced according to the state of the art rules for cold form foams (e.g. G. Woods "Flexible Polyurethane Foams", Chemistry and Technology, 1982, 206 ff).
The crucial factor in this case however, is that care is taken to keep the code number in the above-mentioned range.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in more detail with reference to the examples which are explained in greater detail below, and to drawings, in which
FIGS. 1 and 2 show properties of the foam material obtained,
FIGS. 3 and 4 sow in different forms, a sound insulating adhesive insulating system as a wall coating, coated on a wall part formed by a profiled metal sheet, which employs the polyurethane soft foam material according to the invention,
FIGS. 5 and 6 show, in different forms corresponding to FIGS. 3 and 4, a sound insulating system as a wall coating with a carpet laid over a decoupler.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION Examples
Various kinds of foam materials were produced according to the following standard formulation:
Composition A:
______________________________________                                    
48.0 parts/wt.                                                            
            polyetherpolyol on a propylene                                
            oxide-ethylene oxide basis (42 mg                             
            KOH/g, mol. wt. 4000)                                         
18.0 parts/wt.                                                            
            castor oil (160 ± 10 mg KOH/g,                             
            equivalent weight. 340 ± 20)                               
26.0 parts/wt.                                                            
            polypropylene glycol (250 mg KOH/g,                           
            mol. wt. 450)                                                 
6.0 parts/wt.                                                             
            polyetherpolyol on a polyethylene                             
            oxide and propylene oxide basis (28                           
            mg KOH/g. mol. wt. 4900)                                      
            (cell regulator)                                              
1.0 parts/wt.                                                             
            distilled water                                               
            (blowing agent)                                               
1.0 parts/wt.                                                             
            additive (such as                                             
            dimethylethanolamine, dibutyltin                              
            dilaurate)                                                    
100.0 parts/wt.                                                           
______________________________________
Composition B:
diphenylmethane-4.4-diisocyanate (NCO content: 31%)
The components A and the components B were then added to the mixing head of a RIM machine in the proportions given in the following table and foamed in a mounted to an open pored foam part. It was removed from the mould after 3 minutes.
The properties of the foam material obtained are given in the table and in FIGS. 1 and 2. The weight per unit volume of the foam material was approx. 120 g/dm3.
              TABLE                                                       
______________________________________                                    
Technical-physical data                                                   
Proportion of                                                             
MDI (31% NCO    Compression hard-                                         
content) to     ness (DIN 53576                                           
                               Modulus of                                 
100 pts./wt.    process C)     elasticity                                 
Code No.                                                                  
       comp. A      20%     30%  50%   N/m.sup.2                          
______________________________________                                    
 KZ 100                                                                   
       44.6 pts./wt.                                                      
                    15      22   32.5 N                                   
                                       ca. 280,000                        
KZ 75  33.5 pts./wt.                                                      
                    13      17   22.5 N                                   
                                       ca. 240,000                        
KZ 65  29.0 pts./wt.                                                      
                    11.0    14.0 20.0 N                                   
                                       ca. 190,000                        
KZ 60  26.8 pts./wt.                                                      
                    8.5     10.0 14.5 N                                   
                                       ca. 170,000                        
KZ 50  22.4 pts./wt.                                                      
                    5.5     7.0  11.0 N                                   
                                       ca. 150,000                        
______________________________________                                    
Determination of the adhesive (frictional) properties was carried         
out as follows:                                                           
Test set-up:                                                              
           1.    Universal testing machine of Fa.                         
                 Frank, Weinheim, type 21004,                             
                 upper plate 50 × 50 mm                             
                 Lower plate 200 × 200 mm.                          
           2.    Sample size 50 × 50 mm                             
           3.    Speed 25 mm/min.                                         
Test       The samples are compressed 4 mm                                
procedure: (force pressure cell 500 N) and the                            
           force applying means of the machine                            
           are zeroed.                                                    
           The plate was then moved upwards at                            
           25 mm/min and the force on separtion                           
           noted. After each sample the plates                            
           were cleaned with cleansing agent                              
           60/95.                                                         
______________________________________
The use of the polyurethane soft foam materials according to the invention will be explained in more detail with reference to FIGS. 4 and 4, and 5 and 6 respectively.
The metal sheet forming the wall part 1 as the substrate has profiles which are followed by the wall coating, which is formed as a moulding, namely an insulation system 3 with a carpet 8 arranged over it, the same thickness of the wall coating always being maintained. The wall coating is applied to the wall part adhesively without having to use glue through the adhesion at position 2 of the insulation system 3 comprising polyurethane soft foam material according to the invention.
The wall coating thus consists of the insulation system, 3 which in turn has as a so-called spring 4, 5, the polyurethane soft foam material and a mass 6 of filled plastics material forming a heavy layer. Local differences in the sound damping ability can be obtained by putting the springs 4, 5 on over part of the surface. If necessary uniform sound damping over the whole surface can be obtained by putting the springs 4, 5 on correspondingly over the whole surface.
The adhesive forces of the springs 4, 5 themselves can be altered almost continuously during the production of the insulation system 3, by corresponding control of the mixture ratio. In addition in the case of substantially uniform thickness and local differences in the sound damping ability only a single, simple question is necessary in which, if necessary, stiffening coatings can be put on additionally. According to FIG. 4 and 5, in covering the wall there is now provided, between the heavy layer 6 and the carpet 8 arranged on top of it, a decoupler 7 of a soft elastic, predominately open pored material, preferably a foam material or fleece or felt that has a similar acoustic effect. This decoupler 7 is applied as a thin layer with a thickness in the region of about 5 mm. The decoupler 7 prevents the reduction of the bending strength which can otherwise be detected when a carpet is placed on the insulating system. Moreover it is surprisingly found that not only is the acoustic effect simultaneously maintained but as a rule it is even improved. In addition such an arrangement is simple to work in the usual manner.

Claims (16)

What is claimed is:
1. Polyurethane foam materials with sound insulating and vibration damping properties, obtainable by reacting a polyisocyanate or polyisocyanate prepolymer with an excess of polyols or mixtures thereof whilst maintaining an NCO index of ≦80, for the purpose of obtaining an adhesive surface and further characterized by a density of 80 to 250 kg/m3, a modulus of elasticity of <300,000 N/m2 and a loss factor of at least 0.4.
2. A process of producing a polyurethane soft foam material according to claim 1, characterized in that the components containing a polyisocyanate or polyisocyanate prepolymer are caused to react with the components containing an excess of polyols whilst maintaining an NCO index of <80, by feeding into the mixture head of a RIM arrangement.
3. An article of manufacture comprising a polyurethane soft foam material with an adhesive surface adhered to a substrate as an insulation system for damping sound insulation, where said substrate optionally contains a layer selected from the group of a heavy layer or a carpet.
4. The article according to claim 3, characterized in that when a carpet is laid on the insulation system a decoupler of soft elastic, predominantly open pored material is arranged between the heavy layer of the insulation system and the carpet.
5. The article according to claim 4, characterized in that the decoupler consists essentially of foam material.
6. The article according to claim 4, characterized in that the decoupler consists essentially of acoustically effective fleece or felt.
7. The article according to claim 4, characterized in that the decoupler is thin, in the region of about 5 mm.
8. The article according to claim 4, characterized in that the layers subsequently added and held by adhesive forces have acoustic damping properties.
9. The article according to claim 3, characterized in that the adhesive coating is formed over the whole or part of said substrate.
10. The article according to claim 3, characterized in that the adhesive layer is provided with covers selected from a member of the group of cardboard, Kraft paper, injectable or hardenable plastics materials.
11. The article of claims 1 or 2 where said NCO index is ≦70.
12. The article of claim 3 where said foam is obtained by reacting a polyisocyanate or polyisocyanate prepolymer with an excess of polyols or mixtures thereof whilst maintaining an NCO index of ≦80 for the purpose of obtaining an adhesive surface and further characterized by a density of 80 to 250 kg/m3, a modulus of elasticity of <300,000 N/m2 and a loss factor of at least 0.4.
13. The article of claims 3 or 12 where said NCO index is ≦70.
14. The article of claims 3, 12 or 13 where said substrate is sheet metal.
15. The article of claims 3, 12 and 13 where said substrate is a vehicle section.
16. The article of claim 15 where said vehicle section is fabricated from sheet metal.
US07/174,692 1987-03-31 1988-03-29 Polyurethane soft foam with sound insulating and vibration damping properties Expired - Lifetime US4839397A (en)

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Application Number Priority Date Filing Date Title
DE3710731 1987-03-31
DE19873710731 DE3710731A1 (en) 1987-03-31 1987-03-31 POLYURETHANE FOAMING FUEL WITH SOUND INSULATING AND ENDOWING PROPERTIES

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US4989314A (en) * 1988-08-12 1991-02-05 Waal Casparus W De Method for preparing a corner profile fit for butting connection of closed channels
US5378733A (en) * 1993-04-09 1995-01-03 Seaward International, Inc. Sound attenuating polymer composites
US5420170A (en) * 1989-12-21 1995-05-30 Basf Aktiengesellschaft Preparation of flexible, soft polyurethane foams having viscoelastic, structure-borne soundproofing properties, and polyoxyalkylene-polyol mixtures which can be used for this purpose
US5451615A (en) * 1994-10-20 1995-09-19 The Dow Chemical Company Process for preparing polyurethane foam in the presence of a hydrocarbon blowing agent
GB2313096A (en) * 1996-05-16 1997-11-19 Perstorp Components Ltd Vehicle panel acoustic absorption liner
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US6054647A (en) * 1997-11-26 2000-04-25 National-Standard Company Grid material for electromagnetic shielding
US6391935B1 (en) 2000-01-31 2002-05-21 Bayer Antwerp, N.V. Viscoelastic polyurethane foams
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US20050043423A1 (en) * 2003-08-20 2005-02-24 Katrina Schmidt Formulated resin component for use in spray-in-place foam system to produce a low density polyurethane foam
US20050245627A1 (en) * 2004-04-28 2005-11-03 Takashima Co., Ltd. (Japan Corporation) Polyurethane foam having deodorization property or antibacterial effect
US20070232711A1 (en) * 2004-05-12 2007-10-04 Hans Frei Flexible Polyurethane Foam
US20090110902A1 (en) * 2004-08-13 2009-04-30 Stankiewicz Gmbh Method for the production of a sound insulation molding with mass and spring
US20090127026A1 (en) * 2005-02-10 2009-05-21 Rogier Theodorus Siardus Maria Mandos Covering Element Comprising a Sound Absorbing Element
WO2008131960A3 (en) * 2007-04-30 2009-06-25 Dow Global Technologies Inc Improved acoustic and impact performance of etic-systems
DE102008014032A1 (en) 2008-03-13 2009-09-17 Bayer Materialscience Ag Polyether polyol composition, useful to produce viscoelastic polyurethane foams, comprises polyether polyols with specific hydroxyl-functionality, -number and propylene oxide content, and renewable raw materials with one hydroxyl group
US20090264547A1 (en) * 2008-02-27 2009-10-22 Bayer Materialscience Ag Visco-elastic polyurethane foam with castor oil
US20090286897A1 (en) * 2006-07-04 2009-11-19 Huntsman International Llc Process for making visco-elastic foams
US20110168217A1 (en) * 2010-01-12 2011-07-14 Neff Raymond A Appliance comprising polyurethane foam
US8809410B2 (en) 2009-10-07 2014-08-19 Huntsman International Llc Process for making a flexible polyurethane foam
US20140349827A1 (en) * 2013-05-27 2014-11-27 Thermo Electron Led Gmbh Laboratory centrifuge having insulated compressor
US10047187B2 (en) * 2010-09-09 2018-08-14 Innovative Urethane, Llc Sugar-based polyurethanes, methods for their preparation, and methods of use thereof
US10766998B2 (en) 2017-11-21 2020-09-08 Covestro Llc Flexible polyurethane foams
US11572433B2 (en) 2021-03-12 2023-02-07 Covestro Llc In-situ formed polyols, a process for their preparation, foams prepared from these in-situ formed polyols and a process for their preparation
US11718705B2 (en) 2021-07-28 2023-08-08 Covestro Llc In-situ formed polyether polyols, a process for their preparation, and a process for the preparation of polyurethane foams
RU2813206C1 (en) * 2023-01-31 2024-02-07 Общество с ограниченной ответственностью "Автопластик" Vibration damping material with foam granules
CN119502381A (en) * 2024-10-09 2025-02-25 德和科技集团股份有限公司 A surface treatment method and system for bonding thermoplastic polyolefin and polyurethane
US12232678B2 (en) 2018-10-12 2025-02-25 BSH Hausgeräte GmbH Domestic appliance, method for producing a domestic appliance and method for dismantling a domestic appliance

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US5420170A (en) * 1989-12-21 1995-05-30 Basf Aktiengesellschaft Preparation of flexible, soft polyurethane foams having viscoelastic, structure-borne soundproofing properties, and polyoxyalkylene-polyol mixtures which can be used for this purpose
US6420447B1 (en) 1991-09-06 2002-07-16 Stankiewicz Gmbh Viscoelastic damping foam having an adhesive surface
US5378733A (en) * 1993-04-09 1995-01-03 Seaward International, Inc. Sound attenuating polymer composites
US5451615A (en) * 1994-10-20 1995-09-19 The Dow Chemical Company Process for preparing polyurethane foam in the presence of a hydrocarbon blowing agent
WO1997038237A3 (en) * 1996-04-08 1998-01-08 Minnesota Mining & Mfg Vibration and shock attenuating articles and a method of attenuating vibrations and shocks therewith
US6251493B1 (en) 1996-04-08 2001-06-26 3M Innovative Properties Company Vibration and shock attenuating articles and method of attenuating vibrations and shocks therewith
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US6054647A (en) * 1997-11-26 2000-04-25 National-Standard Company Grid material for electromagnetic shielding
US20030044580A1 (en) * 1999-10-14 2003-03-06 Gorowlcz Janusz P. Headliner having integrated energy absorbing foam
US7261933B2 (en) 1999-10-14 2007-08-28 Gorowicz Janusz P Headliner having integrated energy absorbing foam
US6500369B1 (en) 1999-10-14 2002-12-31 Janusz P. Gorowicz Method of making a headliner having integrated energy absorbing foam
US6391935B1 (en) 2000-01-31 2002-05-21 Bayer Antwerp, N.V. Viscoelastic polyurethane foams
US20030151274A1 (en) * 2000-05-29 2003-08-14 Claude Buisson Lightweight vehicle flooring assembly
US6676199B2 (en) * 2000-05-29 2004-01-13 Rieter Automotive (International) Ag Lightweight vehicle flooring assembly
US6946497B2 (en) 2001-04-27 2005-09-20 Huntsman International Llc Process for making visco-elastic foam
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US6734220B2 (en) 2002-08-27 2004-05-11 Foamex L.P. Fine cell, high density viscoelastic polyurethane foams
US6653363B1 (en) 2002-12-04 2003-11-25 Foamex, L.P. Low energy-loss, high firmness, temperature sensitive polyurethane foams
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US20050043423A1 (en) * 2003-08-20 2005-02-24 Katrina Schmidt Formulated resin component for use in spray-in-place foam system to produce a low density polyurethane foam
US20050245627A1 (en) * 2004-04-28 2005-11-03 Takashima Co., Ltd. (Japan Corporation) Polyurethane foam having deodorization property or antibacterial effect
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US20070232711A1 (en) * 2004-05-12 2007-10-04 Hans Frei Flexible Polyurethane Foam
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US20090110902A1 (en) * 2004-08-13 2009-04-30 Stankiewicz Gmbh Method for the production of a sound insulation molding with mass and spring
US8080193B2 (en) * 2004-08-13 2011-12-20 Stankiewicz Gmbh Method for the production of a sound insulation molding with mass and spring
US20090127026A1 (en) * 2005-02-10 2009-05-21 Rogier Theodorus Siardus Maria Mandos Covering Element Comprising a Sound Absorbing Element
US7964519B2 (en) * 2005-02-10 2011-06-21 Polynorm Plastics B.V. Covering element comprising a sound absorbing element
US20090286897A1 (en) * 2006-07-04 2009-11-19 Huntsman International Llc Process for making visco-elastic foams
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US20090264547A1 (en) * 2008-02-27 2009-10-22 Bayer Materialscience Ag Visco-elastic polyurethane foam with castor oil
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US8809410B2 (en) 2009-10-07 2014-08-19 Huntsman International Llc Process for making a flexible polyurethane foam
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RU2813206C1 (en) * 2023-01-31 2024-02-07 Общество с ограниченной ответственностью "Автопластик" Vibration damping material with foam granules
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